Particulate handling

ABSTRACT

Apparatus and method for filling at least a pair of drums substantially simultaneously whilst minimising the manual handling of the drums. The apparatus includes an inlet port, at least two outlet ports and division means for substantially dividing a stream of pellets entering the hopper via the inlet port and direct a stream of pellets towards each outlet port.

[0001] This application relates to particulate handling apparatus, andin particular to a hopper for use in the loading of catalyst pelletsinto drums.

[0002] It is frequently desired to load catalyst pellets into drumseither for the transportation or storage of said catalyst pellets. Thereare generally two locations where catalyst pellets are loaded intodrums. The first is at the point of manufacture of the catalyst pelletsand the other is adjacent to a reactor vessel that contains catalystpellets which is being emptied either for work to be carried out on thereactor itself, or for treatment or replacement of the catalyst pellets.

[0003] At the point of manufacture of the catalyst pellets the drums areloaded using apparatus that is fixed in one position and which is notthe subject of the present application. When drums are being loadedadjacent to a reactor vessel, the apparatus being used for loading saiddrums must in itself be portable. It would be economically veryinefficient to have all the requisite apparatus for loading andunloading a reactor vessel permanently stationed adjacent to saidreactor vessel.

[0004] Currently known apparatus for use in loading catalyst pelletsinto drums include a hopper, a hopper support frame, and optionally aroller conveyor. In operation, an empty drum is placed beneath thehopper either directly onto the surface supporting the apparatus (hereafter “the floor”) or, if one is being used, on the roller conveyor. Thedrum is open ended and the open end placed upmost and directly beneaththe hopper. The drum is loaded from the hopper and the open end or mouthof the drum then sealed. The drum is then either man-handled frombeneath the hopper or, if a roller conveyor is being used, is rolled outfrom beneath the hopper. The drum is then man-handled onto a palletsuitable for one or more drums and subsequently removed from the area ofthe hopper by a fork lift truck. This is unsatisfactory in that itrequires manual labour to move the filled drums. Manhandling the drumsendangers the people handling the drums because of the weight of thedrums and, potentially, because of the drum contents and the danger ofeither contamination of the outside of the drum or the lid becomingunsealed from the drum during the handling process.

[0005] According to the present invention there is provided apparatusfor the filling at least a pair of drums substantially simultaneouslywhilst minimising the manual handling of said drums.

[0006] According to the present invention there is provided a loadinghopper, in which the hopper is provided with an inlet port, at least twooutlet ports, and division means arranged to substantially divide astream of pellets entering the hopper via the inlet port and direct thedivided stream of pellets towards each outlet port.

[0007] The term ‘pellet’ includes particulate material, shaped or formedbodies, or the like.

[0008] The division means may include the walls of the hopper which areshaped and dimensioned to substantially divide a stream of pelletsentering the hopper via the inlet port and direct a stream of pelletstowards each outlet port.

[0009] In a preferred embodiment of the present invention, the hopper isprovided with a pair of outlet ports. However, the apparatus of thepresent invention may be configured to operate equally effectively withother numbers of outlet ports, most preferably three or four outletports.

[0010] In a particularly preferred embodiment of the present inventionthe hopper is provided with two outlet ports and is so shaped andconfigured that the bisection of the stream of pellets is by way of thestream of pellets impacting an edge defined by the intersection of apair of side walls of the hopper. Said side walls preferably intersectat an acute angle so presenting a bisecting edge which may be asubstantially sharp edge to a stream of pellets entering the hopper viathe inlet port. In this particular preferred embodiment of the presentinvention the side walls which define the bisecting edge also form apart of a substantially conical or pyramidal construction which narrowstoward its vertically lower end to an outlet port. The substantiallypyramidal or conical construction serves to direct the pellets to thefirst and second outlet ports of the hopper.

[0011] In an alternative embodiment of the present invention the streamof pellets may be bisected by one or more baffles or dividing plateslocated within the hopper. Said baffles or dividing plates arepreferably supported in their correct position by being anchored orfixed to one or more side walls of the hopper.

[0012] Using baffles or dividing plates gives a designer of a hopperaccording to the present invention a degree of freedom over the designof the outer wall of the hopper.

[0013] In the most preferred embodiment of the present invention thestream of catalyst pellets enters the hopper with a substantiallyvertically downward direction. The pellets then travel under the forceof gravity past the division or bisecting means and, thence, to theoutlet ports.

[0014] Most preferably the catalyst pellets are transported to thehopper entrained with a conveying gas. The conveying gas is mostpreferably drawn out of said hopper not via the outlet ports, but rathervia one or more conveying gas outlet ports. Each conveying gas outletport is preferably located in such a position that it is very unlikelythat any catalyst pellets entering the hopper would travel from thehopper inlet port to the conveying gas outlet port.

[0015] The conveying gas outlet ports are preferably attached, viaducting, to a means for inducing negative pressure relative to thepressure within the hopper, so causing conveying gas to exhaust from thehopper via the conveying gas outlet ports.

[0016] It is particularly preferred that the hopper is provided with atleast one aperture adjacent to each outlet port.

[0017] Each aperture is sealed with a transparent sheet of material soas to form viewing windows in the hopper. These viewing windows allow anoperator of said hopper to ascertain the conditions within the hopperand, in particular, how full or empty the hopper is.

[0018] Engaged with each outlet port is a reversible port closure meansor valve to which, on the side remote from the hopper, there is attacheda first end of a flexible hose or duct. Attached to the second end ofeach flexible hose or duct is a drum filling lid of known type. Eachdrum filling lid is essentially adapted to sealingly engage with theopen mouth of a drum. The sealing engagement is adapted to be reversibleso as to allow the removal of the drum filling lid once the drum isfull.

[0019] In a most preferred embodiment of the present invention the drumfilling lids adapted to be engaged with the outlet ports are all fixedto a support frame. In an alternative embodiment of the presentinvention each drum filling lid is independently fixed on its ownsupport frame.

[0020] It is preferred that the drum filling lid is provided with meansto create a negative pressure in the drum being filled when the drumfiller lid is sealingly engaged with the drum mouth. Particularlypreferred apparatus for inducing a negative pressure in the drum isprovision of a dust line, or small bore pipe or duct, which providescommunication for gas and dust between the inside of the drum, andeither the inside of the hopper in the region of the conveying gasoutlet port or ports, or directly into the duct or pipe connected with aconveying gas outlet port.

[0021] The apparatus of the present invention may further be providedwith a hopper support frame. The hopper support frame preferablyincludes at least two support posts which may be either permanently orreleasably fixed to the hopper. The support frame may, optionally,include one or more cross members fixing the support posts relative toeach other.

[0022] It is particularly preferred that the support posts aretelescopic so that the apparatus may be adapted for use with drumsand/or pallets of different vertical heights.

[0023] The lower end of each support post is, preferably, fixed to across bar which, at either end of said cross bar, engages with groundengaging means. This provides stability to the hopper and the supportframe. It is particularly preferred that the ground engaging means foreach cross bar are rollers, endless belt tracks, wheels or the like, soallowing the apparatus of the present invention to be rolled, assumingthe surface on which it is resting is sufficiently flat and smooth. Inone particularly preferred embodiment of the present invention theorientation of the axis of rotation of the rollers is fixed andsubstantially parallel and substantially perpendicular to theorientation of the longitudinal axis of each cross bar.

[0024] The support frame or frames for the drum filling lids are mountedon the hopper support frame and are so constructed and configured thatthey allow movement of the drum filling lids either together orseparately between a first retracted position and a second extendedposition. Both retracted and extended positions are at vertically lowerlevels than the hopper outlet ports, when the hopper is orientated foruse, with the retracted position being at a vertically higher level thanthe extended position.

[0025] The attachment of the or each drum filling lid support frame tothe hopper support frame results in the hopper support frame supportingthe weight of the drum filling lids when they are not sealingly engagedwith the mouth of a drum.

[0026] The hopper support frame is so dimensioned and configured that itsupports the hopper in such a position that the level of the mouth of adrum when ready for filling whilst that drum is sitting on a palletsuitable for lifting with a fork lift truck is between the levels of theretracted and extended positions of the drum filler lids.

[0027] In use, the apparatus of the present invention having two outletports is transported by known means, such as a lorry, to a positionadjacent to a reactor vessel. It is then connected with an appropriate,known, catalyst pellet transportation means.

[0028] An operator then checks that the outlet port closure means are ina closed position and that the drum filling lids are in thesubstantially retracted position. A fork lift truck is employed to placea pallet bearing two or four empty drums, their mouths all facingvertically upwards, between the support posts and cross bars of thehopper support frame. The support frame or frames for the drum fillerlids are then manipulated to move the drum filler lids to engage withthe mouth of an empty drum. The filling lids are sealed to the mouths ofthe drums. If necessary, the operator can adjust the telescopic legs (ifpresent) of the hopper support frame to ensure that the drum filler lidsmay engage with the mouth of the drums.

[0029] The drums with which the filler lids are engaged are next placedunder negative pressure by known means not discussed herein. Theoperator of the apparatus then opens the closure means to each outletport causing catalyst to flow, both under the force of gravity and thepressure differential between the hopper and the drum, into the drum.Placing each drum under negative pressure relative to the hopper avoidsneeding to place an air lock or air vent in the drum filling lids.

[0030] When each drum is full, the operator closes the appropriateoutlet port closure means and disengages each drum filling lid from themouth of the now filled drum. The drum filling lids are then moved backto their retracted position and the mouths of the now full drums sealed.

[0031] If the pallet has four drums located on it, the apparatus of thepresent invention is next rolled so that the drum filling lids arevertically above the mouths of the two remaining empty drums and theprocess for filling the drums is repeated. The force needed for rollingthe apparatus of the present invention between the filling positions mayeither be provided by a human, or by a motor, for instance an electricmotor.

[0032] Once all four drums are full, a fork lift truck is employed topick up the pallet bearing the full drums and to transport it to aposition of storage or onto a vehicle for transportation. A fresh palletbearing empty drums is then placed beneath the apparatus of the presentinvention and the above described actions repeated, with the exceptionof the initial setting up adjustments.

[0033] The apparatus of the present invention is particularlyadvantageous over currently known apparatus for drum filling bothbecause of the minimalisation of the manual effort needed to handle thedrums, and because of the increased loading rates for drums. Thepreviously known apparatus only loaded one drum at a time, whereas thepresent apparatus loads at least two drums at a time. Furthermore, thepresent apparatus allows the use of bigger drums which would previouslynot have been usable because of the difficulty of handling said drumswhen full.

[0034] The apparatus of the present invention will be further describedand explained by way of example with reference to the accompanyingFIGURE which represents a schematic view of the apparatus of the presentinvention.

[0035] With reference to the FIGURE, a hopper (2) is defined by walls(4, 6, 8, 10 and others not visible in the FIGURE) so as to create avolume that is comprised of a rectangular volume descending from whichare two substantially pyramidal volumes. The two substantially pyramidalvolumes and the rectangular volume intersect at a bisecting edge (12).

[0036] Substantially vertically above bisecting edge (12) is an inletport (14) into the hopper. The inlet port (14) is adapted to engage withknown apparatus for the transportation of particulate catalysts whenentrained in a conveying gas. The hopper (2) is provided with first andsecond outlet ports (16A, 16B respectively) and viewing windows (20).Not shown are conveying gas outlet ports. Said conveying gas outletports are located adjacent to the vertically uppermost edge of the faceof hopper (2) opposite to viewing windows (20). Each conveying gasoutlet port is in communication with a means for inducing negativepressure and, hence, for sucking conveying gas out of hopper (2).

[0037] Attached to each outlet port (16A and 16B) is a plate valve (18Aand 18B respectively) Said plate valves (18A and 18B) may, by manualoperation, be reversibly moved from an open position whereby catalystpellets can flow through said plate valve to a closed position wherebycatalyst pellets are prevented from exiting hopper (2).

[0038] In communication with the mouth of each plate valve (18A, 18B)remote from hopper (2) is a flexible hose (22A and 22B respectively).The ends of the flexible hoses (22A and 22B) remote from the platevalves (18A and 18B) are each engaged with and in communication with adrum filling lid (24A and 24B). The drum filling lids (24A and 24B) areprovided with means, not shown, for sealingly engaging with the openmouth of a drum. Furthermore, each of the drum filling lids (24A and24B) is provided with an aperture through said filling lid with whichthe respective hoses (22A and 22B) are in communication, and with meansadapted to create a negative pressure in the drum when the filling lidis sealingly engaged with the mouth of the drum.

[0039] Both of the drum filling lids (24A and 24B) are fixed to asupport frame (26). The support frame (26) is, in turn, mounted on ahopper support frame (28). Support frame (26) is so constructed thatwith a single lever action by an operator, the drum filling lids (24Aand 24B) may be moved from the retracted position into engagement withthe mouths of a pair of empty drums which would, when the apparatus werein use, be located in the position shown by dashed lines (38A and 38B).

[0040] Hopper support frame (28) is comprised of a pair of supportposts(30), the upper ends of which are attached to hopper (2). Supportposts (30) are preferably telescopic and constructed in a known fashion.The advantage of support posts (30) being telescopic is that in additionto allowing the overall height of the apparatus of the present inventionabove the surface upon which it is supported to be adjusted, it enablesthe apparatus of the present invention to be packed to a smaller volumefor transportation.

[0041] The lower ends of posts (30) are affixed to cross bars (32).Cross bars (32) engage the surface upon which the apparatus of thepresent invention is resting via fixed direction rollers (34). Therollers (34) are so configured and attached to cross bars (32) that theapparatus of the present invention may be rolled over a flat and hardsurface in directions parallel to the principal axis of cross bars (32).

[0042] In use, the apparatus of the present invention is used asdescribed above.

1. A loading hopper which includes an inlet port, at least two outletports, and division means arranged to substantially divide a stream ofpellets entering the hopper via the inlet port and direct a stream ofpellets towards each outlet port.
 2. A loading hopper according to claim1, wherein the division means includes the walls of the hopper beingshaped and configured so as to substantially divide a stream of pellets.3. A hopper according to claim 1 or 2 which includes two, three or fouroutlet ports.
 4. A hopper according to any preceding claim, wherein eachoutlet port is shaped and configured such that bisection of the streamof pellets is by way of the stream of pellets impacting an edge definedby the intersection of a pair of side walls of the hopper.
 5. A hopperaccording to claim 4, wherein the side walls intersect at an acute angleso presenting a bisecting edge (which may be a substantially sharp edge)to a stream of pellets entering the hopper via the inlet port.
 6. Ahopper according to claim 5, wherein the side walls which define thebisecting edge also form a part of a substantially conical or pyramidalconstruction which narrows toward its vertically lower end to an outletport.
 7. A hopper according to any preceding claim, wherein the divisionmeans includes one or more baffles or dividing plates located within thehopper.
 8. A hopper according to claim 7, wherein the baffles ordividing plates are supported in position by anchoring or fixing meansto one or more side walls of the hopper.
 9. A hopper according to anypreceding claim wherein the pellets are transported to the hopper in aconveying gas, the conveying gas is preferably drawn out of the hoppervia a conveying gas outlet port.
 10. A hopper according to claim 9,wherein the conveying gas outlet port is attached to means for inducingnegative pressure relative to the pressure within the hopper so causingconveying gas to exhaust from the hopper via the conveying gas outletport.
 11. A hopper according to any preceding claim which includes atleast one aperture adjacent to each outlet port.
 12. A hopper accordingto claim 11, wherein the aperture is sealed with a transparent sheet ofmaterial so as to form a viewing window.
 13. A hopper according to anypreceding claim which further includes a hopper support frame typicallyhaving at least one support post which may be permanently or releasablyfixed to the hopper.
 14. A hopper according to claim 13, wherein thesupport post is a telescopic post.
 15. A hopper according to claim 13 or14, wherein the support post is permanently or releasably fixed to thehopper.
 16. A hopper according to any of claims 13 to 15, wherein thehopper support frame includes ground engaging means.
 17. A hopperaccording to claim 16, wherein the ground engaging means includesrollers, wheels, endless belt tracks or the like.
 18. A hopper accordingto any preceding claim, wherein each outlet port has a reversible portclosure means.
 19. A hopper according to claim 18, wherein the portclosure means is attached to at least one drum filling lid.
 20. A hopperaccording to claim 18 or 19, wherein the port closure means is attachedto the drum filling lid by means of a flexible hose.
 21. A hopperaccording to any of claims 18 to 20, wherein the drum filling lid isprovided with means to create a negative pressure in the drum beingfilled when the drum filler lid is sealingly engaged with the drummouth.
 22. A hopper according to claim 21, wherein the apparatus forinducing a negative pressure in the drum includes a dust line, or smallbore pipe or duct, which provides communication for gas and dust betweenthe inside of the drum, and either the inside of the hopper in theregion of the conveying gas outlet port or ports, or directly into theduct or pipe connected with a conveying gas outlet port.
 23. A Hopperaccording to any of claims 18 to 22, wherein the drum filling lid ismounted on the hopper support frame and is so constructed and configuredthat movement of each drum filling lid is permitted (either together orseparately) between a first retracted position and a second extendedposition.
 24. A hopper according to any of claims 16 to 23, wherein eachdrum filling lid which is adapted to be engaged with the outlet portsare either fixed to the hopper support frame, or are fixed to a separatelid support frame.
 25. A method of transferring pellets from a hopper,which method includes: positioning a hopper according to any of claim 1to 24 having pellets therein above at least two drums; and permittingthe pellets to exit the outlet ports and to enter the drums.
 26. Amethod according to claim 25, wherein, the pellets exit the outlet portsunder the force of gravity.